Liquid hydrocarbon sorbing and solidifying pillow

ABSTRACT

A device for collection and containment of spilled or leaked liquid hydrocarbons absorbs pollutants that come in contact. The absorbed material is solidified within the pillow into a rubber-like mass. An impermeable layer of material may be utilized in forming the bottom layer of the outer envelope of the device to retain accumulated hydrocarbons within the pillow while further allowing the contaminants to disperse throughout the device for absorption and solidification. The impermeable layer prevents spilled or leaked hydrocarbons from contaminating the surface below the device. The consolidated mass is easily retrieved and handled for disposal. A variety of options may be utilized in disposing of the spent device, including recycling the rubber-like mass as a component of tar-like materials, such as asphalt. The solidified hydrocarbons will not leech when exposed to pressure limits used to determine landfill suitability.

This application is a continuation of application Ser. No. 08/506,091filed Jul. 24, 1995, now U.S. Pat. No. 5,588,785 which is acontinuation-in-part of application Ser. No. 08/222,844 filed Apr. 5,1994, now U.S. Pat. No. 5,462,785.

BACKGROUND OF THE INVENTION

The present invention relates to absorbent devices for use in containingand disposing of spilled or leaked hydrocarbons. The device furtherprovides a variety of environmentally sound disposal options for spilledand leaked liquid hydrocarbons.

In a broad range of applications, there is a need to contain and removeliquid hydrocarbons that are spilled or leaked into the environment aspart of the routine maintenance and operation of a wide variety ofequipment and machinery utilizing liquid hydrocarbon products for fueland lubrication. This critically important task is necessary to preventpollution of the environment, by for example, entry of pollutants intoan adjacent water column as the spilled or leaked liquid hydrocarbonsseep through the ground, or allowing the hydrocarbons to flow downstreamas waste water runoff.

One common approach to the task of removing spilled or leaked liquidhydrocarbons is to utilize absorbent devices to contain such spills. Awide variety of components, including cotton, peat moss, rice hulls andground-up corn cobs are used in the fabrication of these devices. Onesuch device relies on ground-up chicken feathers encased in a cottonpillow case. The largest class of sorbent devices are typically composedof a group of non-woven, petro-chemical based fabric materials havingthe physical properties of sorbing liquid hydrocarbons while repellingwater. These devices are packaged as flat pads or sheets, or are rolledinto cylindrical booms for placement to absorb and retain leaks andspills caused by the equipment. They are also packaged as strips of thenon-woven fabric encased in an open weave plastic net, resulting in asausage-like boom.

In each instance, these devices are placed in sump or containment areaswhere spilled or leaked hydrocarbons accumulate to absorb and collectthem for extraction from the area.

Prior art absorbent devices of this type are subject to allowing liquidhydrocarbons to pass through the device and on to the surface where theyare placed. The contaminants are then free to soak into the ground andpollute the adjacent area or stain the surface, such as a concrete pad,with a film of liquid hydrocarbons. Further, the absorbed liquidhydrocarbons are subject to release by gravity, column weight or outsideforces exerting pressure on the devices as they are removed from thecontainment area. Disposal of these devices results in the displacementof a substantial volume of the absorbed liquid hydrocarbon pollutantsfrom one environment to another.

SUMMARY OF THE INVENTION

In accordance with the present invention, an absorbent device isprovided which not only absorbs liquid hydrocarbons, but also solidifiesliquid hydrocarbons into an easily retrievable solid rubber-like mass.Further, the present invention may utilize an impermeable layer ofmaterial to form one layer of the outer envelope of the device, allowingthe pillow-shaped device to retain accumulated hydrocarbons within thepillow. Sorbed contaminants coming into contact with the interior sideof the impermeable layer allows the device to disperse liquidhydrocarbons throughout the pillow for further absorption andsolidification. The impermeable layer prevents spilled or leakedhydrocarbons from passing through the device and contaminating thesurface below the device.

The device is formed as a pillow from a textile material sewn to formlayered chambers in stratification contained within an outer envelopewhich defines the overall pillow shape. A seam joinder extending alongthe contiguous sides of the device consolidates the internallystratified layers with the outer envelope layers along theirperipheries.

One or more seams may be placed on or parallel to the longitudinalcenter axis of the pillow to create columns of stratified pockets.Cross-seams may be placed from one side of the pillow to the oppositeside of the pillow, crossing the center axis of the pillow in aperpendicular alignment. Similarly, seams may be placed across thepillow in an oblique orientation to the longitudinal center axis of thepillow. The addition of such seams results in a quilting effect andserves to produce a calculated number and arrangement of chamberscontaining an approximately equal amount of solidifying polymer. Thedesign and spacing of the seams creates multiple consolidation points ofthe stratified layers, the consolidation points acting as flow channelsand defining multiple compartmented absorption cells to facilitate andhasten the migration of the spilled or leaked hydrocarbon contaminantsto the solidifying polymer, followed by the absorption andsolidification of the spill or leak.

The seaming of the textile material components, and the impermeableouter envelope layer of the device, if included, may be accomplished byseveral methods including mechanical stitching, thermal sealing andultra-sonic fusing. These seaming methods may be used to seal theperimeter of the pillow, produce the individual chambers of solidifyingpolymer and unite the stratified internal layers with the outerenvelope. The joining of the layers of textile material results in aseries of consolidation points of the layers of textile material andcreates the flow channels throughout the body of the pillow formigration of spills and leaks to the absorptive cells within the pillow.

The solidifying polymer may be placed in the pillow using severaldifferent methods. As a first example, approximately equally measuredamounts of the polymer may be placed into the open end of the pillowafter the bottom and sides of the internally stratified layers oftextile material and the outer envelope layers of the device have beenseamed together along their periphery by a seam joinder, creating astratified arrangement of pockets. The inserted polymer collects at thebottom of the pockets and is sealed into the body of the device by theseam joinder of the stratified layers, creating a plurality ofpolymer-filled chambers in stratification within the outer envelope ofthe device.

One or more seams may be placed on or parallel to the longitudinalcenter axis of the pillow as it is being formed to create an arrangementof side-by-side elongated pockets. During the filling of the stratifiedarrangement of pockets, a seam may be placed across the center axis ofthe device, forming a plurality of stratified polymer-filled chambers.The step of introducing polymer into the open end of the pillow thensealing it into the chambers by placing a cross-seam may be repeateduntil all the stratified chambers have been formed to create a matrixarrangement of polymer-filled chambers stratified within the outerenvelope of the pillow. Cross-seaming the device to form a matrix ofchambers acts to provide a quilting effect that may be desired in orderto increase the rate of migration of the hydrocarbons to the interior ofthe pillow by the creation of consolidation points and flow channelswithin the body of the device.

Cross-seaming the device may also be accomplished by placing seams in anoblique orientation to the center axis of the device. The placement ofan arrangement of seams in an oblique orientation forms a comparablematrix of chambers within the device to provide a similar quiltingeffect that may be desired in order to increase the rate of migration ofthe hydrocarbons to the interior of the pillow by the creation ofconsolidation points and flow channels within the body of the device.

Other methods of stratifying and sealing the solidifying polymer withinthe outer envelope of the device may be used. One method calls for thesolidifying polymer to be encased and sealed within individual bags ofsingle layer textile material. Each bag is filled with a measured amountof the solidifying polymer and sealed to form a solitary chamber ofsolidifying polymer within a single layer of textile material.Individual bags may then be arranged side-by-side in a matrixconfiguration of rows and columns to produce a single layer of bagsconforming to the designated perimeter dimensions of the finishedpillow. Identical layers of the arrangement of polymer-filled bags maybe duplicated and then stratified over the first layer of bags toproduce the required thickness of the pillow. Each layer of thearrangement of bags may be positioned so the perimeter of the overallshape of the layer and the side-by-side intersections of the matrix ofbags in each layer are aligned in substantial registration with thecorresponding perimeter of the arrangement of bags and the side-by-sideintersections of the arranged bags of the other layers.

The stratified layers of individual polymer-filled bags may then beenclosed within an outer envelope and sealed within the perimeter of theouter envelope by a seam joinder. The intersections of the individualpolymer-filled bags of the stratified layers may be seamed to the outerenvelope of the pillow, creating flow channels and consolidating pointsof the stratified layers and producing a quilting effect in theformation of the device. The solidifying polymer may also be suspendedwithin the fibers of a textile material as they are being formed, or maybe attached to the textile material. The suspending of the polymer maybe accomplished by incorporating the polymer into the body of the fabricduring the process used to form the textile material. This process isnormally used in the production of melt-blown or spunbonded textiles.The manufacturing of a synthetic textile fabric material starts with rawpetro-chemical based pellets, such as polypropylene, being blended withpigments and/or additives. This mixture is heated to the melting pointof the pellets and extruded into filaments. The filaments are drawn andattenuated, using high velocity air to align the polymer molecules andmaximize fiber strength. The resulting continuous, high tenacityfilaments are formed into a web on a moving conveyor screen andthermally fused together with a bonding system to maximize the strengthand surface stability of the fabric. The polymer may be suspended withinthe fabric by adding it to the mix of raw petro-chemical based pellets,pigments and additives, melting the mixture and extruding filaments fromthe mixture. This method incorporates the polymer into the body of thefilaments as they are formed.

The polymer may also be suspended within the fabric by injecting anevenly distributed amount of the polymer at an intermediate point as theweb of filaments are formed on the conveyor screen. As the filaments arethermally fused together with the bonding system, the polymer is trappedwithin the fused filaments, becoming a component of the finished textilefabric material.

The polymer may be suspended within pockets in the fabric by fusinglayers of textile material with a calendaring device having thecapability of producing a pattern in the fused layers of textilematerial as it exits the bonding mechanism. An approximately evenlydistributed amount of the polymer may be placed in a pattern,corresponding to the pattern of the calendaring device, on a layer oftextile material filaments as it moves along a conveyor screen. A secondlayer comprising a web of textile material filaments may then be placedover the first web of filaments having the pattern of evenly distributedamounts of polymer positioned on it prior to introducing the layers ofthe material to the calendaring device. As the filaments of the twolayers of material are thermally fused together by the bonding system,the polymer is trapped within pockets created by the calendaring deviceused to fuse the filaments, allowing the polymer to become a componentof the finished textile fabric material.

An evenly distributed, measured amount of the polymer may also beattached to textile material by using an adhesive to bond the polymer toa layer of material. The layers of textile material holding the polymerwithin its web of filaments or bonded to the polymer may then bestratified between two layers of material forming the outer envelope ofthe device and sealed within the perimeter of the outer envelope of thepillow with a seam joinder. Longitudinal, lateral or oblique seams maybe added to the device, if desired, to produce a quilting effect.

In each instance, the solidifying polymer is stratified and arrangedbetween layers of textile material within a device formed by the outerenvelope, with additional seams providing a quilting effect for theentire device, if desired.

Quilting of the pillow creates a series of continuous consolidationpoints of the internally stratified layers of textile material withinthe pillow envelope. The textile material absorbs the spilled or leakedliquid hydrocarbons on contact. This action, coupled with the continuousconsolidation points of the layers of textile material and the uniquestratification design of the chambered pillow, speeds migration of theliquid hydrocarbons throughout the interior of the pillow through theflow channels created by the seam joinder and the quilting seams via thecapillary attraction of the liquid hydrocarbons to the textile material.The result is a uniform distribution of the liquid hydrocarbonsthroughout the entire structure of the pillow for absorption andsolidification by the solidifying polymer within the stratified layersof the pillow.

Typically, the density and weight of the internal layers of stratifiedtextile material may be substantially less than the density and weightof the textile material used to form the outer envelope of the pillow.This reduces the volume of liquid hydrocarbons that may be retainedwithin the textile material segments of the pillow in the event thevolume of the spill or leak exceeds of the capacity of the solidifyingpolymer within the pillow. Pillows fabricated utilizing thinner textilematerials of less dense construction typically retain smaller volumes ofliquid hydrocarbons within the textile material components of the pillowthan devices fabricated using materials of greater density.

Chemical composition, thickness and density of the fibers utilized inthe composition of a textile material play a critically governing rolein controlling the rate of absorption and the ratio of retention of theliquid hydrocarbons being sorbed by the material. Textile materialsformed by using a greater density of thicker fibers are sturdier andmore resistant to tearing than textile materials composed of thinnerfibers or formed in a less dense configuration. Thus, a heavier materialmay be used to form the outer envelope to add to the structuralintegrity and durability of the envelope while lighter textile materialmay be used to form the internally stratified chambers of solidifyingpolymer. The migration of the sorbed liquid hydrocarbons throughout theinterior of the pillow via the capillary attraction of the liquidhydrocarbons to the textile material remains a characteristic while thelevel of retention of the liquid hydrocarbons diminishes.

The utilization of an impermeable layer of material, such aspolyethylene, to form the bottom layer of the outer envelope serves toprevent sorbed liquid hydrocarbons from passing through the body of thedevice and on to the surface where the device has been placed ininstances where the solidifying polymer may not have the required amountof time to solidify the spilled or leaked contaminants. The impermeableouter envelope layer may further enhance the effectiveness of the deviceas it serves to spreads the liquid contaminants throughout the body ofthe device for absorption and solidification.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the preferred embodiments of theinvention in which:

FIG. 1 is a top view of a first embodiment of a device in accordancewith the present invention showing its pillow-shaped envelope form, theseams creating consolidation points of the outer envelope with theinternally stratified layers of textile material along the longitudinaland lateral axes of the device, and the seams sewn on four sides;

FIG. 2 is an exploded illustration of the first embodiment of the devicein FIG. 1, showing alternating layers of textile material andsolidifying polymer arranged to conform to the desired dimensions of thepillow and stratified to the desired thickness of the pillow within anouter envelope;

FIG. 3 shows the detail of a seam that may be used to consolidate theinternally stratified layers of textile material with the outer envelopeof the pillow and to seal the stratified layers of polymer within theperimeter of the device in FIG. 1;

FIG. 4 shows the detail of a seam that may be used along thelongitudinal axis and the cross-seams of the pillow to consolidate theinternally stratified layers of textile material with the outer envelopeof the device in FIG. 1;

FIG. 5 shows a cross section of the first embodiment of the device inFIG. 1, indicating the chambers filled with polymer separated by thetextile material and the consolidation of the outer envelope with theinternal layers of textile material at the edges and at the seam alongthe center axis of the pillow;

FIG. 6 is an exploded illustration of a second embodiment of the devicein FIG. 1 in accordance with the present invention wherein the polymeris encased in a plurality of rectangular single-layer bags arranged toconform to the desired dimensions of the pillow and stratified to thedesired thickness of the pillow with the junctions of the individualpolymer-filled bags of each layer being in substantial registration withthe corresponding junctions of individual polymer-filled bags of theother layers within an outer envelope;

FIG. 7 shows a series of polymer-filled and sealed bags of single layerfabrication joined by an ultra-sonic seam. This method of seaming may beused to encase the polymer in each of the individual bags, to seal thestratified layers within the outer envelope along the perimeter of thepillow and to create the consolidation seams of the outer envelope withthe stratified layers of the device;

FIG. 8 shows a cross section of the second embodiment of the device inFIG. 1, indicating the stratified layers of individual polymer-filledbags encased within an outer envelope and the consolidation of the outerenvelope with the outer edges and the internal junctions of thesubstantially registered stratified layers of individual polymer-filledbags;

FIG. 9 is an exploded illustration a third embodiment of the device inFIG. 1 in accordance with the present invention wherein layers oftextile material, with an evenly distributed, measured amount of polymersuspended within the web of filaments of the textile material, arearranged and stratified to conform to the desired dimensions of thedevice within an outer envelope;

FIG. 10 shows a cross section of the third embodiment of the device inFIG. 1, indicating the layers of textile material, with an evenlydistributed, measured amount of polymer suspended within the web offilaments of the textile material, arranged in stratification within anouter envelope with the internally stratified layers of textile materialand suspended polymer and the outer envelope consolidated by seaming atthe edges and along the center axis of the device.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In FIG. 1, an absorbent device 1 in accordance with the presentinvention is shown in a pillow-shaped configuration formed by anenvelope 2 with seaming of the four sides 2a, 2b, 2c, and 2d. This seamis shown in greater detail in FIG. 3. A longitudinal seam 20 is shownsewn along the center axis of the pillow, and lateral seams 21, 22, 23,24, 25, 26, and 27 are shown sewn at evenly spaced intervals from oneside of the pillow to the opposite side of the pillow and crossing thelongitudinal seam along the center axis seam of the pillow in aperpendicular orientation. These seams are shown in greater detail inFIG. 4. Grommets 28 and 29 are placed on the longitudinal seam along thecenter axis seam of the pillow on each end of the pillow, providing anattachment point to allow the user to tether the device in place orserve as a connecting point with other pillows to form a continuousboom. FIG. 2 is an exploded illustration of the first embodiment of thedevice in FIG. 1, showing alternating layers of textile material 4 and 6and solidifying polymer 3, 5, and 7 in a stratified arrangement betweenthe layer of textile material 2 and the layer of impermeable material 2xcomprising the outer envelope of the device.

Referring to FIG. 5, the cross section of the first embodiment of thepillow prior to closure at seam 2d reveals the stratification design ofthe pillow achieved by stacking pieces of textile material 2, 4 and 6and the layer of impermeable material 2x and seaming them at points 2a,2b and 2c. The resulting pockets are arranged one on top of another andenclosed by an outer envelope of layers 2 and 2x. Next, a seam 20 may besewn along the center axis of the pillow, providing a line of additionalconsolidating points of the internally stratified layers of textilematerial with the outer envelope of the pillow along its longitudinalaxis and creating two columns of pockets 11, 12, and 13 and 14, 15, and16 within the device. FIG. 5 shows the effect of alternatemulti-layering of textile material layers 2, 4, 6 and 2x and theconsolidation of the layers along seams 2a, 2b, 2c and 20 to formpockets 11, 12, 13, 14, 15, and 16. These pockets are then filled withpolymer and sealed into the body of the pillow, resulting in anarrangement of stratified polymer-filled chambers.

The polymer may be inserted into the device by placing a measured amountof the polymer in each pocket at the open end of the device and allowingthe polymer to drop through the pockets until it is contained by seam2b. The polymer may then be sealed in the pockets with lateral seam 21,sewn from seam 2a to seam 2c and crossing seam 20 at a perpendicularangle. Seam 21 seals the polymer into chambers and creates an additionalline of consolidation points of the layers of textile material. Thesealing of the polymer into chambers results in an even distribution ofthe polymer throughout the device as it prevents loose polymer frommigrating throughout the body of the device and clustering in a fewareas.

The filling process may be repeated, allowing the polymer to dropthrough the pockets until it is contained by seam 21 with seam 22 sewnto form the next section of stratified polymer-filled chambers. Theprocess may be repeated until the last section of pockets is filled withpolymer. The last section of polymer-filled chambers and the pillow isseamed shut by seam 2d.

The internally stratified layers of textile material are consolidatedwith the outer envelope of the pillow at the seams 2a, 2b, 2c and 2daround the perimeter of the pillow, and at seams 20, 21, 22, 23, 24, 25,26, and 27 along the longitudinal and lateral axes of the device. Thisallows liquid hydrocarbons that come in contact with the outer envelopelayers 2 and 2x to migrate via the seams 2a, 2b, 2c, 2d, 20, 21, 22, 23,24, 25, 26, and 27 under capillary attraction to the interior layers oftextile material 4 and 6 and propagate throughout the pillow.

In accordance with the first embodiment directed to containment sumpsand the like, the pillow envelope 2 measures 48"×6"×1/4". Each pillowchamber contains approximately 12 grams by weight of the solidifyingpolymer material for an approximate total weight of 576 grams of polymerin the pillow. The textile material is preferably a petro-chemical basedfabric such as polypropylene, polyester or nylon. The layer ofimpermeable material is preferably a sheet of a petro-chemical basedmaterial such as polyethylene or the like. The polymer material ispreferably an elastomer polymer under the trademark WASTE-SET 3200,WASTE-SET 3400, NOCHAR A610, NOCHAR A650, ENVIRO BOND 403, NORSOREXAPX1, H-100ENVIRONMENTAL SPILL ENCAPSULANT or an equivalent.

FIG. 6 is an exploded illustration of the second embodiment of thedevice in FIG. 1, showing stratified layers of individual polymer-filledbags 30, 31 and 32 in a stratified arrangement between the layers 2 and2x comprising the outer envelope of the device.

In accordance with a modification of the second embodiment, the layer oftextile material 2 comprising the outer envelope of the device may beeliminated from the structure. If this form of the second embodiment isimplemented, the typical density of the material for the individualpolymer-filled bags may be on the order of 2.0 ounce. A suitablematerial for use is polypropylene or a similar synthetic fabric. Thus,with reference to FIG. 6, the modified device would include the layersof individual polymer-filled bags 30, 31 and 32 in the same stratifiedarrangement, but without the layer of textile material 2 forming theouter envelope. Of course, the consolidation and seaming of thestratified layers with the layer of impermeable material 2x that resultsin a quilting effect (see FIG. 8) remains applicable to the modifiedsecond embodiment without outer envelope layer 2.

Referring to FIG. 7, a series of polymer-filled and sealed bags ofsingle layer textile material are shown joined by ultrasonic seams. Thismethod of seaming may be used to encase the polymer in each of theindividual bags, to seal the stratified layers within the outer envelopealong the perimeter of the pillow and to create the consolidation seamsof the outer envelope with the stratified layers of the device.

Referring to FIG. 8, the cross section of the second embodiment of thedevice prior to closure at seam 2d reveals the stratification design ofthe pillow achieved by stratifying layers of individual polymer-filledbags 33, 34, 35, 36, 37 and 38 between outer envelope layers 2 and 2x.The outer edges of the internal layers of polymer-filled bags areconsolidated with the outer edges of the materials forming the outerenvelope of the device along seams 2a, 2b and 2c. Seam 20 is sewn alongthe center axis of the pillow and seams 21, 22, 23, 24, 25, and 26 aresewn laterally across the pillow to consolidate the outer envelopelayers with the internal layers along the junctions of the substantiallyregistered stratified layers of individual polymer-filled bags.

FIG. 8 shows the effect of the stratified layering of individualpolymer-filled bags 33, 34, 35, 36, 37 and 38 between the outer envelopelayers 2 and 2x and the consolidation of the layers along seams 2a, 2b,2c and 20 21, 22, 23, 24, 25 and 26 to form an arrangement ofpolymer-filled chambers within the body of the device. The internallystratified layers of individual polymer-filled bags are consolidatedwith the outer envelope of the pillow at the seams 2a, 2b, 2c and 2daround the perimeter of the pillow, and at seams 20, 21, 22, 23, 24, 25,and 26 along the longitudinal and lateral axes of the device.

These seams allow liquid hydrocarbons that come in contact with thetextile material outer envelope layer 2 to migrate via the seams 2a, 2b,2c, 2d, 20, 21, 22, 23, 24, 25, 26, and 27 under capillary attraction tothe interior layers of individual polymer-filled bags 33, 34, 35, 36, 37and 38 and propagate throughout the pillow.

In accordance with the second embodiment directed to containment sumpsand the like, the pillow envelope 2 measures 48"×6"×1/4". Each pillowchamber contains approximately 12 grams by weight of the solidifyingpolymer material for an approximate total weight of 576 grams of polymerin the pillow. The textile material is preferably a petro-chemical basedfabric such as polypropylene, polyester or nylon. The layer ofimpermeable material is preferably a sheet of a petro-chemical basedmaterial such as polyethylene or the like. The polymer material ispreferably an elastomer polymer under the trademark WASTE-SET 3200,WASTE-SET 3400, NOCHAR A610, NOCHAR A650, ENVIRO-BOND 403, NORSOREXAPX1, H-100 ENVIRONMENTAL SPILL ENCAPSULANT or an equivalent.

FIG. 9 is an exploded illustration of the third embodiment of the devicein FIG. 1, showing layers of solidifying polymer suspended in textilematerial 40, 41 and 42 in a stratified arrangement between layers 2 and2x comprising the outer envelope of the device.

In accordance with a modification of the third embodiment, the layer oftextile material 2 comprising the outer envelope of the device may beeliminated from the structure. If this form of the third embodiment isimplemented, the typical density of any single layer of polymersuspended in textile material may be on the order of 2.0 ounce. Asuitable material for use is polypropylene or a similar syntheticfabric. Thus, with reference to FIG. 9, the modified device wouldinclude the layers of polymer suspended in textile material 43, 44 and45 in the same stratified arrangement, but without the layer of textilematerial 2 forming the outer envelope. Of course, the consolidation andseaming of the stratified layers with the layer of impermeable material2x that results in a quilting effect (see FIG. 10) remains applicable tothe modified third embodiment without outer envelope layer 2.

Referring to FIG. 10, the cross section of the third embodiment of thedevice prior to closure at seam 2d reveals the stratification design ofthe pillow achieved by stratifying layers of polymer suspended intextile material 43, 44 and 45 between outer envelope layers 2 and 2xand seaming them at points 2a, 2b and 2c using the seam illustrated inFIG. 3. Seam 20 may be sewn along the center axis of the pillow,providing a line of additional consolidating points of the internallystratified layers of polymer suspended in textile material with theouter envelope of the pillow along its longitudinal axis and creatingtwo columns of internally stratified layers of polymer suspended intextile material 43, 44 and 45, and 46, 47 and 48 within the device.FIG. 10 shows the effect of the stratified layering of polymer suspendedin textile material 43, 44 and 45, and 46, and 48 between the outerenvelope layers 2 and 2x and the consolidation of the layers along seams2a, 2b, 2c and 20, 21, 22, 23, 24, 25 and 26 to form an arrangement ofpolymer-filled chambers within the body of the device.

These seams allow liquid hydrocarbons that come in contact with theouter envelope layer 2 to migrate via the seams 2a, 2b, 2c, 2d, 20, 21,22, 23, 24, 25, 26, and 27 under capillary attraction to the interiorstratified layers of polymer suspended in textile material 43, 44 and45, and 46, 47 and 48 and propagate throughout the pillow.

In accordance with the third embodiment directed to containment sumpsand the like, the pillow envelope 2 measures 48"×6"×1/4". Each layer ofpolymer suspended in textile material contains approximately 192 gramsby weight of the solidifying polymer material for an approximate totalweight of 576 grams of polymer in the pillow. The textile material ispreferably a petro-chemical based fabric such as polypropylene,polyester or nylon. The layer of impermeable material is preferably asheet of a petro-chemical based material such as polyethylene or thelike. The polymer material is preferably an elastomer polymer under thetrademark WASTE-SET 3200, WASTE-SET 3400, NOCHAR A610, NOCHAR A650,ENVIRO-BOND 403, NORSOREX APX1, H-100 ENVIRONMENTAL SPILL ENCAPSULANT oran equivalent.

Ambient temperature and the viscosity of the liquid hydrocarbon to besolidified are the two most critical factors in determining the rate ofabsorption and the amount of time required to solidify the broadspectrum of liquid hydrocarbons this invention is designed to containfor removal and disposal. To enhance the polymer's effective interactionwith pollutants, the pillow's construction utilizes the layering ofpolymer material and textile material to control the rate of absorptionand solidification.

The properties of the textile material that allow for rapid absorptionand migration of all viscosities of liquid hydrocarbons effectively givethe device maximum surface area exposure of the polymer through the mostbasic stratification design of the outer envelope with the internallystratified layers.

The effectiveness of the pillow may be enhanced with the addition ofquilting seams. A longitudinal seam 20 along the center axis of thepillow and lateral seams 21, 22, 23, 24, 25, 26 and 27 perpendicular tothe center axis of the pillow provide consolidation points of theinternally stratified layers of textile material with the externaltextile material envelope and forms chambers within the pillow. Theconsolidation of the internal layers of textile material within theouter envelope speeds migration of the liquid hydrocarbons throughoutthe interior stratified layers of the pillow via the capillaryattraction of the liquid hydrocarbons to the textile material. Thelateral seams may also be oriented at an oblique angle to the centeraxis of the pillow. In either case, a quilted effect is achieved. Also,a plurality of seams may be placed parallel to the longitudinal centeraxis instead of a single seam located on the longitudinal center axis.Further, a similar quilting effect may be achieved by placing aplurality of seams that cross the pillow at oblique angles to oneanother so as to form the pockets in diamond, rather than square orrectangular, shapes. Other quilting designs may also be used.

The stratification design allows for optimum efficiency in utilizing thesolidifying properties of the polymer. Very light viscosity liquidhydrocarbons react almost instantaneously with the polymer and areexposed to no more polymer than can be fully utilized for absorption andsolidification. Stratification promotes rapid migration of lightviscosity liquid hydrocarbons throughout the interior of the pillowwhile slowing migration of the liquid hydrocarbon through the outersurface envelope area and exposure to the polymer. The extremely rapidreaction between the light viscosity liquid hydrocarbon and the polymercould otherwise result in the loose polymer located within the volume ofthe pillow being surrounded by a non-permeable rubber shell. Theresulting surface blockage would thereby prevent the enclosed polymerfrom being used to solidify additional liquid hydrocarbons.

In addition, the stratification design allows the heavier viscosityliquid hydrocarbons that migrate through the layers of textile materialto be suspended inside the pillow awaiting the polymer to absorb themand begin the solidification process.

A combination of the embodiments may be desirable to further enhance theeffectiveness of the pillow. For instance, the placement of a layer ofsolidifying polymer 7 (see FIG. 2) from the first embodiment of thedevice between the layer of impermeable material 2x and the adjacentstratified layer of polymer suspended in textile material 42 (see FIG.9) of the third embodiment of the device may serve to increase the totalliquid hydrocarbon uptake and retention capacity of the pillow.Solidifying polymer layer 7 (see FIG. 2) from the first embodiment ofthe device may similarly be placed between the layer of impermeablematerial 2x and the adjacent stratified layer of individualpolymer-filled bags 32 (see FIG. 6) of the second embodiment.

Devices of this type may be used to collect and contain spills and leaksfrom the containment sumps, generally found beneath equipment andmachinery using liquid hydrocarbons for fuel and lubrication, forremoval and disposal. The devices may further be utilized in a widevariety of applications including, but are not limited to, removal ofliquid hydrocarbons from beneath motorized vehicles, electricitytransformers, petrochemical pipelines, printing presses, aircraft,railroad equipment and fuel and lubricant containers.

The foregoing description of the preferred embodiment has been for thepurpose of explanation and illustration. It will be appreciated by thoseskilled in the art that many modifications and changes may be made inthe structure without departing from the essence of the presentinvention. For example, certain types of treated paper products may besubstituted for the textile material or the layer of impermeablematerial. Therefore, it is contemplated that the appended claims willcover any modifications or embodiments which fall within the scope ofthe invention.

What is claimed is:
 1. A liquid hydrocarbon absorbent devicecomprising:a pillow having a plurality of stacked fabric layersdispersively conducting liquid hydrocarbons under capillary attractionsubstantially throughout the pillow, each fabric layer comprising aplurality of pockets formed by a pattern of fused interconnectionsbetween first and second layers of textile material such that theplurality of stacked fabric layers forms a plurality of pockets instratification within the pillow; a polymer material contained withinthe pillow to absorb and solidify liquid hydrocarbon substances, saidpolymer material being suspended within said pockets; and a seam joinderof the peripheries of the layers to promote migration of liquidhydrocarbons under capillary attraction to the pockets.
 2. The device ofclaim 1 further comprising an outer envelope surrounding the stackedfabric layers.
 3. The device of claim 2 wherein the outer envelopecomprises first and second layers of textile material that sandwich thestacked fabric layers.
 4. The device of claim 2 wherein the outerenvelope comprises an outer facing layer of an impermeable materialextending over a surface of the pillow and acting to retain liquidswithin the pillow.
 5. The device of claim 2 wherein the seam joinder ofthe outer envelope and the stacked fabric layers promotes migration ofliquid hydrocarbons under capillary attraction to the pockets.
 6. Thedevice of claim 1 wherein the polymer material is an elastomer polymer.7. A liquid hydrocarbon absorbent device comprising:a pillow having aplurality of stacked fabric layers dispersively conducting liquidhydrocarbons under capillary attraction substantially throughout thepillow, each fabric layer comprising a plurality of pockets formed by apattern of fused interconnections between first and second layers oftextile material such that the plurality of stacked fabric layers formsa plurality of pockets in stratification within the pillow; a polymermaterial contained within the pillow to absorb and solidify liquidhydrocarbon substances, said polymer material being suspended withinsaid pockets; a series of seams formed in the pillow providingconsolidation points of the internally stratified pockets so as topromote dispersion of liquid hydrocarbons throughout the interior of thepillow to the polymer material; and a seam joinder of the peripheries ofthe layers to promote migration of liquid hydrocarbons under capillaryattraction to the pockets.
 8. The device of claim 7 further comprisingan outer envelope surrounding the stacked fabric layers.
 9. The deviceof claim 8 wherein the outer envelope comprises first and second layersof textile material that sandwich the stacked fabric layers.
 10. Thedevice of claim 8 wherein the outer envelope comprises an outer facinglayer of an impermeable material extending over a surface of the pillowand acting to retain liquids within the pillow.
 11. The device of claim8 wherein the seam joinder of the outer envelope and the stacked fabriclayers promotes migration of liquid hydrocarbons under capillaryattraction to the pockets.
 12. The device of claim 8 wherein the seriesof seams formed in the pillow provides consolidation points of the outerenvelope and the stacked fabric layers to promote migration of liquidhydrocarbons under capillary attraction to the pockets.
 13. The deviceof claim 7 wherein the polymer material is an elastomer polymer.